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Rework bracket for electrical outlet boxesRework bracket for electrical outlet boxes description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070164183, Rework bracket for electrical outlet boxes. Brief Patent Description - Full Patent Description - Patent Application Claims
[0001]This application claims priority from provisional application Ser. No. 60/755,275, filed on Dec. 30, 2005, which is incorporated herein in its entirety. FIELD OF THE INVENTION [0002]The present invention relates to brackets used to install electrical outlet boxes in a wall. In particular, the invention relates to brackets that are used to install electrical outlet boxes in existing walls. BACKGROUND OF INVENTION [0003]The use of electrical outlet boxes for housing electrical devices and connecting wires is well known in the art. In new construction, the boxes are typically attached to wall studs using screws or nails prior to placement of the wall on the studs. Conventional fasteners may be used in these situations to mount the boxes to the wall studs. In many cases, the outlet boxes include tabs or apertures for mounting the boxes. However, when electrical boxes are installed in existing walls, such as when renovating or remodeling, the wall studs are not always readily accessible or in the desired location to permit easy installation of the electrical boxes. These situations require the use of "cut-in" or "old work" electrical boxes, which do not have to be attached to a stud or support member. [0004]Cut-in" or "old work" boxes, are used where the boxes are inserted into an opening cut into the wall. The boxes are specifically constructed to include clamping hardware, which enables the box to be clamped to the wall about the opening without regard to the location of the wall studs. These cut-in or old work boxes have a variety of designs and many of them use a bracket or similar type of mounting hardware to secure the box to the wall. [0005]Cut-in" or "old work" boxes generally take two forms. The first includes boxes having swing-out clips. Examples of boxes of this type are shown in U.S. Pat. Nos. 4,332,330, 2,299,696, 2,272,846 and 1,957,844. The boxes shown in these patents include adjustable clips mounted on each box side wall. The clips are initially positioned inside the outer perimeter of the box so that the box may be inserted into an opening in the wall which is sized to specifically accommodate the box. After the clips pass through the opening, they may be swung outwardly to engage the back surface of the wall. These swing-out clips, however, are difficult to manipulate in the tight environment in which these boxes must be installed. Further, the box must include passageways or slots through the side wall of the box to enable the clip to swing out from an internal position to an external position once the box is inserted through the wall opening. As may be appreciated, boxes having swing-out clips of this type require extensive fabrication and/or modification of an existing box structure. Due to such extensive modification, many of these types of cut-in boxes are not listed by agencies such as Underwriters Laboratories (UL) and Canadian Standards Association (CSA). [0006]Another type of cut-in box includes those boxes which have clips and screws mounted on the exterior surface of the side walls or the top and bottom walls of the box. Examples of boxes of this type are shown in U.S. Pat. Nos. 2,867,344, 2,801,019, 1,957,003 and 1,775,665. As the clips shown in these patents are mounted exteriorly of the box, they present a wide profile which requires a larger hole to be cut through the wall into which the box is to be mounted. Such a large opening may require extensive wall repair after the box is installed or must be used with a large cover plate to cover the opening. [0007]Also, many of these boxes include complicated wall engaging mounting structures. Compression devices, toggle clips, snaps and the like such as shown in U.S. Pat. Nos. 4,120,473, 4,120,416, 2,776,774, 2,870,931 and 2,769,562 may also be used to secure the box to the wall. However many of these structures are difficult for the installer to easily operate. [0008]Common to all of the above described boxes, is the fact that the boxes must be prefabricated or specifically modified to accommodate particular mounting hardware. This necessitates the installer carrying boxes which are specifically manufactured solely for old work or cut-in applications in addition to boxes for other applications. [0009]Therefore, it is desirable to provide a mounting bracket which allows for the use of a standard electrical box in old work or cut-in applications. SUMMARY OF THE INVENTION [0010]In accordance with the present invention, a bracket for an electrical outlet box is provided. The bracket includes a first end section, a middle section and a second end section. Each section has a first side, a second side, a top surface and a bottom surface. The end sections have substantially planar surfaces and the top surface of the middle section is offset from, and preferably substantially parallel to, the top surfaces of the first and second end sections. Preferably, the middle section is substantially planar and is offset from the first end section by the first offset portion and from the second end section by the second offset portion. In another embodiment, the middle section is arcuately shaped and directly connected to the first and second end sections, or connected by the first and second offset portions. Preferably, the surfaces of the first and second end sections are in substantially the same plane. The middle section can include a bendable member that extends from the first side of the middle section in substantially the same plane as the middle section and the bendable member can have an aperture. In one embodiment, the bendable member extends outwardly from the first side of the middle section and upwardly in relation to the top surface of the middle section. In this embodiment, the middle section includes one or more tangs, which extend outwardly from the top surface and can engage, preferably in a flexible manner, the outside wall of an electrical outlet box. [0011]The bracket also includes first and second opposing ends which extend upwardly and substantially perpendicular to the top surfaces of the first and second end sections. The opposing ends have first and second sides which correspond to the first and second sides of the first, second and middle sections. A first tab and a second tab extend in opposing relation to each other from the first side of the first and second end sections. In addition, a first leg and a second leg extend downwardly from the second side of the bottom surfaces of the first and second end sections to a first and a second bottom edge, respectively. Preferably, the first and second legs are substantially flat and each of the first and second bottom edges comprises a notch. In preferred embodiments, the first and second legs extend downwardly along more than one half of the first and second lengths of the first and second end sections. [0012]The bracket can be made from non-ferrous or steel sheet metal and, preferably, is made as a unitary construction, that is, the bracket is fabricated from a single piece of sheet metal. The preferred method of fabrication is by a stamping process, which forms the bracket (i.e., cuts out the shape of the bracket from a piece of sheet metal) in a single operation and then shapes the bracket (i.e., bends the different sections) in subsequent operations. [0013]The preferred embodiments of the bracket of the present invention, as well as other objects, features and advantages of this invention, will be apparent from the following detailed description, which is to be read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE FIGURES [0014]Other objects and many attendant features of this invention will be readily appreciated as the invention becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: [0015]FIG. 1 is a top perspective view of the rework bracket. [0016]FIG. 2 is a side perspective view of the rework bracket. [0017]FIG. 3 is a bottom perspective view of the rework bracket. [0018]FIG. 4 is a side view of the first side of the rework bracket. [0019]FIG. 5 is a bottom view of the rework bracket. [0020]FIG. 6 is a side view of the second side of the rework bracket. 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